Method of making a motorcycle seat

ABSTRACT

A tandem motorcycle seat for attachment to the frame of an associated motorcycle has a unitary, rigid, elongated platform member configured to seat upon and be secured to the frame of the motorcycle, and an elongated tandem saddle on the platform member providing drive and passenger seat portions. A backrest for a person seated on one of the seat portions has a depending leg spaced inwardly from the side margins of the saddle which extends through a passage in the saddle into a receptacle on a bracket secured to the platform member. In making the seat, a first layer of a mixture of glass fibers and polyester resin is embedded on the lower element of a mold which is configured to form the platform member of the seat. Hardware is applied on the first layer and a second layer of glass fiber/resin is applied to the first layer and about the hardware so as to encapsulate at least a portion of the hardware in the layers which are then partially cured. A foamable synthetic resin is introduced into the lower element of the mold onto the partially cured second layer. The first and second layers and the foamable synthetic resin are concurrently cured to produce a chemical bond between the glass reinforced layers and foam layer and the composite seat body is removed from the mold and covered with a pliable outer layer of material.

This is a divisional of application Ser. No. 08/377,650 filed on Jan.25, 1995, now U.S. Pat. No. 5,544,937.

BACKGROUND OF THE INVENTION

The present invention relates to a tandem motorcycle seat, and, moreparticularly, to a tandem motorcycle seat which has a backrest which maybe selectively positioned to support either driver or passenger, and toa method for molding such motorcycle seats.

Tandem motorcycle seats are frequently used for touring, and comfort isa significant concern. Additionally, it is often viewed as important tomaintain an aesthetically pleasing and streamlined look to themotorcycle seat. Often, these objectives may conflict with one another.

Although a tandem motorcycle seat is designed to accommodate a passengerbehind the driver, it is frequently occupied by only the driver.Therefore, a backrest for such a seat could be positioned behind thepassenger, the driver, or both, or even omitted. If it is removable,safety considerations require that the backrest be securely positionedwhen mounted.

It is an object of the present invention to provide a novel tandemmotorcycle seat which offers flexibility of configuration throughselective positioning of a backrest.

It is also an object to provide such a seat that will maintain anaesthetic streamlined appearance when the backrest is not in use.

Another object is to provide such a seat which will safely secure thebackrest.

A further object to provide such a seat which is rugged and durable andable to withstand adverse weather and road conditions.

An additional object is to provide a novel method for molding motorcycleseats which effects a strong bond between the cushioning layer and theunderlying structural layer of the seat and between the several layersand the hardware.

SUMMARY OF THE INVENTION

It has now been found that the foregoing and related objects may bereadily attained in a tandem motorcycle seat for attachment to the frameof a motorcycle and having a unitary rigid, elongated platform memberconfigured to seat upon and be secured to the frame of the motorcyclefor firm support thereby. The platform member has front and rear endsand side margins, and it supports an elongated tandem saddle whichprovides a driver seat portion at its front end and a passenger seatportion at its rear end. Support members on the platform member arepositioned adjacent the rear end of each of the seat portions andintermediate the side margins thereof, and each provides an upwardlyopening receptacle. The tandem saddle has openings therethrough alignedwith the receptacles of the support members. A backrest for a personseated on one of the seat portions has a depending leg spaced inwardlyfrom the side margins thereof and extending through one of said passagesin the saddle. The leg has its lower end releasably seated in thereceptacle aligned therewith, and the backrest is movable from one seatportion to the other seat portion.

Preferably, the support means includes means releasably locking thelower end of the leg in the receptacle. The receptacle is desirablyprovided by a tubular member cooperatively dimensioned and configured toseat the lower end of the leg therewithin. The support means alsoincludes a bracket mounted on the platform member and securing thetubular member thereto. Preferably, the bracket is mounted on the lowersurface of the platform member and the lower surface of the platformmember is configured to seat the brackets.

The means releasably locking the lower end of the leg is typically anelongated member passing through the tubular member and through thelower end of the leg therewithin to releasably lock the lower end of theleg within the tubular member.

The backrest preferably includes a body member pivotally mounted on theleg adjacent the upper end thereof and means for limiting the pivotalmovement of the body member in a direction rearwardly of the saddle. Themeans for limiting the pivotal movement is desirably an elongated memberpassing through the upper end of the leg above the pivot point andabutting the body member of the backrest.

Desirably, the saddle includes closure elements releasably secured overthe passages therein.

In an improved method for making a motorcycle seat, there is provided amold dimensioned and configured to form a unitary rigid, elongated bodyconfigured to seat upon and be secured to the frame of the motorcyclefor firm support thereby. The mold has a lower element and an upperelement, and a first layer of a mixture of glass fibers and polyesterresin is applied to the surface of the lower mold element. Hardware isplaced in this first layer, and a second layer of a mixture of glassfibers and polyester resin is applied on the first layer and hardware soas to encapsulate at least a portion of the hardware in the first layerand the second layer. The first layer and the second layer are partiallycured, and a foamable synthetic resin is introduced into the lowerelement of the mold and onto the partially cured second layer and aboutthe hardware. The upper element of the mold is interfitted with thelower element of the mold, and the first and second layers and thefoamable synthetic resin form are then fully and concurrently cured inthe assembled mold to produce a chemical bond between the second layerand the synthetic resin foam layer to provide the seat body. The uppermold element is removed, and the seat body is removed from the mold andis then covered with an outer layer of flexible material.

Preferably, the lower mold element is formed with small cavities in itsupper surface, and some of the hardware is inserted through the firstlayer into the cavities. Before the covering is applied, the excess formlayer is trimmed. The preferred foamable resin is polyurethane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view of a motorcycle with a tandemseat embodying the present invention;

FIG. 2 is a perspective view drawn to an enlarged scale of a supportmember used to releasably mount the backrest in the embodiment of FIG.1;

FIG. 3 is a perspective view of the depending leg of the backrest usedin the embodiment of FIG. 1 and drawn to the same scale as FIG. 2;

FIG. 4 is a fragmentary, partially exploded perspective view of thebackrest drawn to an enlarged scale, and with portions broken away toreveal internal construction;

FIG. 5 is a fragmentary sectional view of the backrest of the tandemmotorcycle seat along the line 5--5 of FIG. 1, and drawn to a furtherenlarged scale;

FIG. 6 is a partially exploded perspective view of the bottom of thetandem motorcycle seat of FIG. 1, shown without the backrest and drawnto an enlarged scale;

FIG. 7 is a sectional view of the tandem motorcycle seat along the line7--7 of FIG. 1, showing the backrest in full line in one position, andin phantom line in an alternate portion;

FIG. 8 is an enlarged portion of the structure in FIG. 7;

FIG. 9 is a perspective view of a mold used to form the body portion ofthe tandem motorcycle seat of the present invention;

FIG. 10 is a sectional view along the line 10--10 of FIG. 9,diagrammatically illustrating hardware being inserted and a brushapplying a glass fiber/resin mixture;

FIGS. 11-13 are schematic illustrations of the several steps in themolding of the seat body; and

FIG. 14 is the seat body after removal from the mold.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning first to FIG. 1, a motorcycle seat embodying the presentinvention is generally designated by the numeral 10 and has a platformmember or base (as shown in FIG. 6) generally designated by the numeral12 secured to the frame or chassis 14 of a motorcycle generallydesignated by the numeral 15. Secured on the top surface of the platformmember 12 is a contoured saddle generally designated by the numeral 16and providing a disposed driver seat portion 18 and a rearwardlydisposed passenger seat portion 20. A backrest generally designated bythe numeral 22 is shown positioned behind the passenger seat portion 20.

The saddle 16 is upholstered and is configured to have its peripheryblend into the adjacent lines of the chassis 14 of the motorcycle 15. Asshown, the seat 10 extends forwardly so that its forward end abuts thegasoline tank 24 of the motorcycle 15. As shown, the passenger seatportion 20 is elevated above the driver seat portion 18, and thehandhold bar 26 is provided above the rear wheel 27 of the motorcycle15.

The saddle 16 has side panels 28 on either side thereof which are of asmooth waterproof material such as vinyl or leather. An accent strip orwelt 30 extends around the sides of the backrest 22, and it may be thesame color as an accent strip or welt 32 around the sides of the saddle16. The covering 34 for the upper surface of the saddle 16 may betextured or smooth and it may be fabricated of leather, vinyl or othersuitable flexible material. Beneath the covering 34 comprising the outersurface of the saddle 16 is a foam layer 114, which is best seen in FIG.7, and which serves to provide comfort to the rider(s). This foam layer114 may be flexible cellular foamed synthetic resin or any otherresiliently deformable material. On the covering 34, directly behind thedriver seat portion 18 and the passenger seat portion 20 are flaps 36which removably cover passages 38, 39 in through the covering 34 and thefoam layer 114 of the saddle 16.

Turning now to FIGS. 6 and 7, the base or platform member 12 isconveniently formed from molded fiberglass reinforced resin, and it isconfigured to closely fit or wrap about the chassis 14 and components ofthe particular motorcycle 15 upon which it is to be mounted. Theplatform member 12 has conventional mounting elements (not shown) on thebottom surface thereof which mate with cooperating retainers (not shown)on the motorcycle chassis 14 to secure it thereto. Desirably, theplatform member 12 has resilient spacers 40 spaced thereabout whichsupport the platform member 12 upon the motorcycle frame 14. Theplatform 12 has a first upwardly extending recess 42 underneath and tothe rear of the driver seat portion 18 and a second upwardly extendingrecess 43 underneath and to the rear of the passenger seat portion 20.

As seen in FIGS. 4 and 5, the backrest 22 has a rigid, generally planarbody member 44 which is oriented generally vertically. A pair ofparallel, horizontally spaced arms 46 extend rearwardly from the bodymember 44 at right angles thereto. The arms 46 are spaced inwardly fromthe side margins of the backrest 22 generally centrally thereof, andhave aligned apertures 48 therein.

As seen in FIGS. 3-5, a depending leg 50 of generally rectangular crosssection has a lower end portion 52 and an upper end portion 54. Theupper end portion 54 of the leg 50 has a bore 56 extending therethroughin alignment with the apertures 48 in the arms 46 between which it isdisposed. A pivot bolt 58 passes through the bore 56 and apertures 48 ofthe arms 46 to pivotally mount the leg 50 to the body member 44 of thebackrest 22, and nut 59 retains the bolt 58 in position.

A second bore 60 in the upper end portion 54 of the leg 50 extends foreand aft and threadably seats a screw 62 which is adjustably positionedin the bore 60 with its forward end thereof abutting the body member 44.Movement of the screw 62 within the bore 60 permits adjustablelimitation of the pivoting of the body member 44 on the depending arm 50in a rearward direction.

A notch 64 in the forward surface of the leg 50 receives the lower edgeof body member 44 when the upper end of the body member 44 pivotsforwardly.

A bore 66 in the lower end portion 52 of the leg 50 receives the lockingscrew 67 and a washer 68 is positioned between the head 69 of thelocking screw 67 and the leg 50.

As best seen in FIG. 4, the body member 44 and the arms 46 areencapsulated between layers 70 of a fiberglass reinforced polyesterresin. A foam layer 72 is placed about the front and around the edges ofthe body member 44 to provide support and comfort for the driver orpassenger. A pliable outer layer 74 of leather, vinyl or the like,surrounds the backrest 22 to provide protection from the elements and anaesthetically pleasing appearance. Optionally, a storage pocket 75 maybe formed in outer layer 74.

Referring to FIGS. 2 and 6-8, each of the pair of brackets 76 hasmounted thereon a tubular member 78 with a generally rectangular crosssection. The bracket 76 has a base leg 81 and an upwardly inclined leg80 against which the tubular member 78 is secured by welding or thelike.

The generally horizontal base leg 81 of the bracket 76 is provided withfour apertures 82 and the inclined leg 80 of the bracket 76 is providedwith a pair of apertures 84 on opposite sides of the tubular member 78and apertures 86 near its lower end to receive the locking screw 67which also extends through aligned apertures 88 in the tubular member78. The locking screw 67 extends through the bore 66 on the leg 50 andthereby releasably locks the lower end portion 52 of the leg 50 in thetubular member 78.

Four studs 90 extend downwardly from the lower surface of the platformmember 12 from a portion adjacent to and in front of each of therecesses 42 and 43 and extend through the apertures 82 in the horizontalbase leg 81 of the bracket 76. Washers 92 and nuts 94 are used to securethe bracket 76 on the studs 90. Bolts 96 extend through apertures 84 inthe upwardly inclined leg 80 of the bracket 76 and into threaded inserts97 in platform member 12 to complete the fastening the bracket 76 to theunderside of platform member 12.

When installing the backrest 22 behind the passenger seat portion 20,the flap 36 in the covering 34 behind the passenger seat portion 20 islifted to expose the passage 39 in the saddle 16. The leg 50 of thebackrest 20 is then slid downwardly through the passage 39 and into thetubular member 78 below the passenger seat portion 20. The locking screw67 is then pushed through the apertures 86 in the bracket 76, theapertures 88 in the tubular element 78 and the bore 66 in the lower endportion 52 of the leg 50. The motorcycle seat 10 is then mounted on theframe 14 of the motorcycle 15, the backrest 22 is adjusted to thedesired angle, and the set screw 62 is used to lock the angle of thebackrest 22 relative to the saddle 16.

When it is desired to move the backrest 22 from a position behind thepassenger seat portion 20 to a position behind the driver seat portion18, the motorcycle seat 10 is unbolted from the frame 14 of themotorcycle 15. The locking screw 67 is then removed from the apertures86, 88 and the bore 66, and the lower end portion 52 of the leg 50 iswithdrawn from the tubular member 78 and the passage 39 in the saddle16. The closure flap 36 in the covering 34 behind the passenger seatportion 20 may then be reseated to restore a streamlined appearance tothe saddle 16. The closure flap 36 in the covering 34 behind the driverseat portion 18 is lifted to expose the passage 38 behind the driverseat portion 18. The lower end portion 52 of the leg 50 can then beinserted downwardly through the passage 38 and into the tubular member78 carried by the bracket 76 mounted below the driver seat portion 18.The locking screw 67 is then installed as described above, themotorcycle seat 10 is again mounted on the frame 14 of the motorcycle15, and the screw 62 used to adjust the angle of the backrest 22relative to the saddle 16.

In fabricating and assembling the motorcycle seat 10, a mold 98 havingboth a lower element 100 and an upper element 102, as shown in FIG. 9,is employed. The mold 98 is dimensioned and configured to form theunitary, rigid, elongated platform member 12 and the foam cushion layer114.

Referring first to FIG. 10, a first layer 104 of a mixture of glassfibers and polyester resin is applied to the upper surface of the lowerelement 100 of the mold 98, typically by means of a brush 106. As can beseen in FIG. 9, there are raised portions 108 in the lower element 100of the mold 98 which serve to form the recesses 42, 43 in the platformto receive the tubular members 78.

Before or after application of the first layer 104, various hardwaresuch as the studs 90 are inserted through the first layer 104 and intocavities 110 in the lower element 100 of the mold 98.

As seen in FIG. 11, a second layer 112 of the mixture of glass fibersand polyester resin is then applied on top of the first layer 104 andthe various hardware so as to encapsulate at least a portion of thehardware in the first layer 104 and the second layer 112. Preferably,fasteners such as bolts and studs with polygonal or elongated heads (notshown) may be used to limit unwanted rotation. Application of the secondlayer 112 is again typically by means of the brush 106. Subsequent toapplication of the second layer 112, both the first layer 104 and thesecond layer 112 are partially cured.

Referring to FIG. 12, a foamable synthetic resin 114 is introduced intothe mold onto the partially cured second layer 112. The foam 114 istypically introduced through a nozzle 116. Subsequently, the upperelement 102 of the mold 98 is locked with the lower element 100. Thecontents of the mold 98 are subjected to heat and pressure to fully andconcurrently cure the resins in the several layers and produce both achemical bond and a mechanical interlocking between the second layer 112and the synthetic resin foam layer 114 to produce the seat body.

As shown in FIG. 14, when the fully cured seat body is removed from themold, there is some excess foam 118 which will typically be trimmed. Atthis point, a flexible outer layer or cover which includes thepreviously mentioned side panels 28 and covering for the upper surface35 shown in FIG. 1 is installed.

The backrest is fabricated and assembled in a similar manner as theplatform member 12 and saddle 16.

Thus, it can be seen from the foregoing detailed specification andattached drawings that the tandem motorcycle seat of the presentinvention provides a flexible configuration through a backrest which maybe selectively positioned behind the driver, the passenger, or both, andmay even be completely removed. Use of a closure flap over the receivingpassages for the backrest permits the seat to maintain an aestheticallypleasing appearance when the backrest is not in use. Additionally, theuse of a locking screw for the backrest when it is in either positionassures safety for the rider and the passenger. The backrest is ofrugged construction and able to tolerate adverse weather and roadconditions.

Having thus described the invention, what is claimed is:
 1. In a methodfor making a motorcycle seat for attachment to the frame of anassociated motorcycle, the steps comprising:(a) providing a molddimensioned and configured to form a unitary, rigid, elongated platformmember configured to seat upon and be secured to the frame of theassociated motorcycle for firm support thereby, said mold having a lowerelement and an upper element; (b) applying a first layer of a mixture ofglass fibers and polyester resin onto the surface of said lower elementof said mold; (c) embedding hardware in said first layer; (d) applying asecond layer of a mixture of glass fibers and polyester resin on saidfirst layer and about said hardware so as to encapsulate at least aportion of said hardware in said first layer and said second layer; (e)partially curing said first layer and said second layer; (f) introducinga foamable synthetic resin into said lower element of said mold on saidpartially cured second layer and about said hardware; (g) interfittingsaid upper element of said mold on said lower element of said mold; (h)curing said first and second layers and said foamable synthetic resin insaid assembled mold to produce a cellular cushioning layer from saidfoamable synthetic resin and to produce a chemical bond between saidsecond layer and said cellular cushioning layer to provide a seat body;(i) removing said upper mold element; and (j) removing said seat bodyfrom said lower mold element.
 2. The method for making a motorcycle seatin accordance with claim 1 including the step of applying a cover offlexible material about said cushioning layer of said seat body.
 3. Themethod for making the tandem motorcycle seat in accordance with claim 1including the step of trimming excess fully cured foam cushioning layerprior to the covering step.
 4. The method for making the tandemmotorcycle seat in accordance with claim 1 wherein said mold providingstep includes providing a lower mold element with hardware receivingcavities therein and said hardware placing step involves inserting someof said hardware through said first layer and into cavities in saidlower mold element.
 5. The method for making the tandem motorcycle seatin accordance with claim 1 wherein said foamable synthetic resin is afoamable polyurethane composition.